U.S. patent application number 17/274271 was filed with the patent office on 2021-10-07 for apparatus and method for processing cups.
The applicant listed for this patent is SACMI COOPERATIVA MECCANICI IMOLA SOCIETA' COOPERATIVA. Invention is credited to Fiorenzo PARRINELLO, Fabrizio PUCCI.
Application Number | 20210308915 17/274271 |
Document ID | / |
Family ID | 1000005720969 |
Filed Date | 2021-10-07 |
United States Patent
Application |
20210308915 |
Kind Code |
A1 |
PUCCI; Fabrizio ; et
al. |
October 7, 2021 |
APPARATUS AND METHOD FOR PROCESSING CUPS
Abstract
An apparatus (1) for processing plastic cups (2), adapted to be
filled with coffee or other products, whether solid or liquid, and
to be closed with respective lids to form corresponding capsules,
comprises: a plurality of pockets (50) for housing the cups (2); an
infeed station (4) for receiving the cups (2) and placing them in
respective pockets (50) of the plurality of pockets (50); at least
one tool (31) for applying a process to a rear face (23B) of an
annular flange (23) of a cup (2) housed a respective pocket (50),
to form a sealing profile (230); an outfeed station (6) configured
to release the cups (2) with the sealing profile (230) formed on
them.
Inventors: |
PUCCI; Fabrizio;
(Castelguelfo (Bologna), IT) ; PARRINELLO; Fiorenzo;
(Medicina (Bologna), IT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SACMI COOPERATIVA MECCANICI IMOLA SOCIETA' COOPERATIVA |
Imola (Bologna) |
|
IT |
|
|
Family ID: |
1000005720969 |
Appl. No.: |
17/274271 |
Filed: |
October 8, 2019 |
PCT Filed: |
October 8, 2019 |
PCT NO: |
PCT/IB2019/058549 |
371 Date: |
March 8, 2021 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 43/361 20130101;
B29L 2031/7164 20130101; B29C 66/112 20130101; B29C 2043/525
20130101; B29C 65/02 20130101; B29C 2793/009 20130101; B29C 43/021
20130101; B29C 2043/3613 20130101; B29C 2043/023 20130101; B29L
2031/7132 20130101; B29C 66/131 20130101; B29C 43/52 20130101; B29C
2793/0054 20130101; B29C 66/0242 20130101; B29C 66/53461 20130101;
B29C 66/0222 20130101; B29L 2031/7174 20130101 |
International
Class: |
B29C 43/02 20060101
B29C043/02; B29C 43/36 20060101 B29C043/36; B29C 43/52 20060101
B29C043/52; B29C 65/02 20060101 B29C065/02; B29C 65/00 20060101
B29C065/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 9, 2018 |
IT |
102018000009295 |
Claims
1.-19. (canceled)
20. An apparatus for processing cups, wherein each cup includes a
containment body, which extends between a bottom wall and an upper
edge, and an annular flange connected to the upper edge and having
a rear face, directed towards the containment body, and a front
face, adapted to receive a lid to form a capsule, the apparatus
comprising: at least one pocket, configured to house a
corresponding cup; at least one tool configured to apply a process
to at least the rear face or the front face of the annular flange
of the cup inside the at least one pocket, so as to form a sealing
profile.
21. The apparatus according to claim 20, comprising: a plurality of
pockets configured to house a corresponding plurality of cups; an
infeed station configured to receive the cups and placing them in
respective pockets of the plurality of pockets and an outfeed
station configured to release the cups, with the sealing profile
formed on them, to an outlet of the apparatus, wherein, the at
least one tool is configured to apply the process to the rear face
of the annular flange of a cup inside a respective pocket of the
plurality of pockets, to form a sealing profile.
22. The apparatus according to claim 21, comprising a rotary
carousel, wherein the pockets of the plurality of pockets are
angularly spaced on the carousel.
23. The apparatus according to claim 22, including, for each pocket
of the plurality of pockets, a respective rotary tool which rotates
as one with the carousel and which is configured to apply a process
to the rear face of the annular flange of the cup inside the
pocket.
24. The apparatus according to claim 20, wherein the at least one
tool is configured to apply a mechanical force on the rear face of
the annular flange of the cup.
25. The apparatus according to claim 20, comprising a corresponding
abutment element associated with the at least one tool, wherein the
at least one tool includes a main body and one or more protrusions
projecting from the main body and wherein the at least one tool and
the corresponding abutment element are movable between an open
configuration, in which they are spaced apart, and a closed
configuration, in which they are close together and the abutment
element is in contact with the front face of the annular flange and
the one or more protrusions of the at least one tool penetrate the
annular flange, impressing the sealing profile therein.
26. The apparatus according to claim 25, wherein the abutment
element is radially symmetric about its axis of symmetry and
includes a contact surface, configured to come into abutment
against the front face of the annular flange, and a centring body
which projects from the contact surface and which, in the closed
configuration, at least partly enters the containment body of the
cup to provide a centring effect on the cup in the respective
pocket.
27. The apparatus according to claim 20, wherein the at least one
tool includes a respective heating element configured to heat the
at least one tool.
28. The apparatus according to claim 20, comprising at least one
heater configured to heat the annular flange of the cup inside the
at least one pocket.
29. The apparatus according to claim 20, comprising a control unit
which is specific to the apparatus and configured to control the at
least one tool.
30. The apparatus according to claim 20, wherein the at least one
tool includes a milling cutter configured to remove material from
the rear face of the annular flange, to form the sealing
profile.
31. The apparatus according to claim 20, wherein the at least one
tool includes a plurality of processing elements and wherein the
apparatus comprises a control unit programmed to selectively switch
on a part of the plurality of processing elements as a function of
the selected type of sealing profile.
32. The apparatus according to claim 31, wherein the processing
elements include laser emitters distributed on a surface to form an
array of laser emitters.
33. The apparatus according to claim 20, comprising: a plurality of
pockets, each pocket configured to house a corresponding cup in a
respective cavity; a rotary carousel, wherein the pockets of the
plurality of pockets are angularly spaced on the carousel; for each
pocket of the rotary carousel, a respective centring device, the
centring device including a first part and a second part, movable
towards and away from each other, wherein each of the first part
and a second part of the centring device delimits a portion of the
cavity.
34. A line for making capsules intended to contain a product,
comprising: a forming machine configured to form plastic cups,
wherein each cup includes a containment body, which extends between
a bottom wall and an upper edge, and an annular flange connected to
the upper edge and having a rear face, directed towards the
containment body, and a front face, opposite to the rear face; and
an apparatus for processing the plastic cups, the apparatus
comprising: at least one pocket, configured to house a
corresponding cup; at least one tool configured to apply a process
to at least the rear face or the front face of the annular flange
of the cup inside the at least one pocket, so as to form a sealing
profile.
35. The line according to claim 34, wherein the forming machine is
configured to form the cups by compression moulding.
36. The line according to claim 34, further comprising: a filling
machine configured to fill the cups with coffee or other solid or
liquid products; an applicator machine, configured to apply a lid
to the front face of each cup to form a respective capsule.
37. The line according to claim 36, wherein the line is configured
to transfer the cups, with the sealing profile formed on them and
released by the outfeed station of the apparatus for processing the
cups, to an infeed station of the filling machine.
38. A method for processing plastic cups adapted to be filled with
coffee or other products, whether solid or liquid, and to be closed
with respective lids to form corresponding capsules, wherein each
cup includes a containment body, which extends between a bottom
wall and an upper edge, and an annular flange connected to the
upper edge and having a rear face, directed towards the containment
body, and a front face, adapted to receive a lid to form a capsule,
the method comprising the following steps: receiving the cups and
placing each cup in a pocket of the apparatus; applying a process
to at least the rear face or the front face of the annular flange
of the cup inside the pocket, so as to form a sealing profile by
means of at least one tool of the apparatus; releasing the cups
with the sealing profile formed on them.
39. The method according to claim 38, wherein the step of applying
the process comprises a step of processing the front face of the
annular flange of the cup to form a knurled zone suitable for
welding the lid.
Description
TECHNICAL FIELD
[0001] This invention relates to an apparatus and a method for
processing plastic cups adapted, for example, to be filled with
coffee and to be closed with respective lids to form coffee
capsules.
BACKGROUND ART
[0002] Known in the sector of beverage production by infusion is
the use of capsules containing infusion material such as coffee,
for example. The capsules comprise a cup and a lid and are designed
to be placed in specific beverage production machines where hot
water or steam is fed into the capsule in order to brew the
beverage.
[0003] In these beverage production machines, the capsule must be
provided with an airtight seal which allows obtaining a pressurized
environment. In many cases, the airtight seal is formed on an
annular flange-like rim of the cup. Known in the prior art are
several apparatuses and methods for forming the airtight seal on
the annular flange-like rim of the capsules.
[0004] Patent documents WO2007/122208A1 and WO2016/007006A2
describe the production of a seal by injection moulding of a
quantity of sealing material on a flange of a preformed capsule to
form a sealing element attached to the capsule flange. Applying a
quantity of sealing material on the capsule to make the seal has
the disadvantage of complicating the production process,
necessitating steps of preparing the quantity of sealing material,
applying the material on the capsule and moulding the material, all
of which results in longer process times and higher production
costs.
[0005] Patent document WO2013046014A1 describes a solution in which
the sealing element comprises a triangular protrusion projecting
from the flanged rim and preferably formed as a single part as one
with the capsule by injection moulding or thermoforming. In
solutions of this kind, the production of the sealing element is
fast but the geometry of the mould needed to obtain a sealing
element of the required shape is necessarily complex. The complex
geometry of the mould gives rise to several problems, including
build-up of dirt in the mould, imprecision in the geometry
obtained, difficulty of completely extracting the air resulting in
the formation of air bubbles. Moreover, the sealing elements can be
made in a very limited range of shapes because every shape requires
a dedicated mould.
[0006] Patent document WO2016075321A1 proposes a solution in which
the steps of forming and filling the capsule are followed by a step
of applying a lid to the flanged rim of the capsule, during which
the lid and the flanged rim are squeezed between a first and a
second tool so as to deform the flanged rim (made at least partly
of a polymeric material) to create a thick portion and a thin
portion; the first and second tools are preferably heated. This
solution has some disadvantages: first of all, after the forming
step, the flanged rim cools down and is cold by the time it reaches
the machine which applies the lid. Thus, to be able to deform it
with a good degree of precision, it must be re-heated from a
temperature close to ambient temperature (normally low) up to a
temperature at which the plastic the flange is made of softens;
this subsequent heating step involves consuming a non-negligible
amount of energy. Moreover, the fact that the seal is made at the
end of the capsule production process (that is to say, when the lid
is applied) means that any fault in the production of a seal leads
to the capsule with that seal being defective and makes it
necessary to reject the entire full capsule (that is to say, not
only the body of the capsule but also the beverage ingredients it
contains and the lid).
DISCLOSURE OF THE INVENTION
[0007] The aim of this disclosure is to provide an apparatus and a
method for processing a capsule intended for the production of a
beverage in a beverage production device to overcome the above
mentioned drawbacks of the prior art.
[0008] This aim is achieved by the apparatus, line and method of
this disclosure as characterized in the appended claims.
[0009] The apparatus of this disclosure is directed to the
processing of plastic cups adapted to be filled with a product. The
cups are then closed by a lid applied to the cup to form the
capsule. Once applied, the lid seals the product inside the
capsule. In an embodiment, the cup (or at least the part of the cup
that is operatively in contact with the lid) is stiffer than the
lid; the lid may be flexible.
[0010] In a possible application, the product is solid (for
example, in powder or granular form), or liquid or creamy. In a
possible application, the product is a food product (solid, in
powder or granular form, or creamy). In an application, the product
is an infusion product; in this case, the capsule is intended to be
inserted into a machine configured to make a beverage by
interaction of a pressure element with the capsule to create a
sealed environment. For example, the product may be coffee;
hereinafter, reference is made to coffee capsules, for convenience
of description, without thereby limiting the scope of the
disclosure to coffee as the only product that can be filled into
the capsules.
[0011] The cups may be made of plastic material (such as, for
example, polymeric or composite materials) and/or metallic material
(for example, aluminium).
[0012] Each cup includes a containment body which extends between a
bottom wall and an upper edge. Each cup also includes an annular
flange (or flange-like rim) having a rear face, directed towards
the containment body, and a front face, adapted to receive the lid
to form the capsule. The annular flange is connected to the upper
edge of the containment body. The annular flange extends radially
from the containment body. The body of the cup thus defines a
recess intended to be filled with coffee or other infusion
material. The apparatus preferably comprises a plurality of pockets
configured to receive (or house) the cups.
[0013] The pockets may include (or be in the form of) cavities into
which the cups are inserted For example, they might be inserted
with bottom wall of the cup resting on the bottom of the pocket; in
this case, the cup received in the pocket is directed with the
recess facing up (that is to say, the concavity defined by the body
of the cup is directed upwards). In addition, or alternatively, the
pockets may include (or be in the form of) flat supporting surfaces
to supportably receive the cups on corresponding surfaces; for
example, the front face of the annular flange might be supported on
the corresponding flat supporting surface of the respective pocket;
in this case, the cup received in the pocket is directed with the
recess facing down (that is to say, the concavity defined by the
body of the cup is directed downwards).
[0014] The apparatus preferably comprises an infeed station
configured to receive the cups (already formed) and to place them
in respective pockets of the plurality of pockets.
[0015] The apparatus comprises at least one tool, configured to
apply a process to the annular flange of a cup which is housed
inside (or received in or supported on) a respective pocket of the
plurality of pockets, so as to form a sealing profile. The
expression "sealing profile" is used to mean a zone of the annular
flange configured to create the seal when the capsule interacts
with the pressure element in the coffee machine.
[0016] Preferably, the tool is configured to apply the process to
the rear face of the annular flange of the cup. In effect, in the
coffee machines in which the capsule will be used, the pressure
element is (at least in one possible embodiment) responsible for
coming into contact with the rear face of the annular flange.
Nevertheless, in an embodiment, the at least one tool is configured
to apply the process (also or only) on the front face of the
annular flange of the cup. In effect, a process on the front face
increases the elasticity of the annular flange so that when the
pressure element of the coffee machine comes into contact with the
rear face, it can deform the area and create a seal; in this case,
too, a sealing profile is made.
[0017] In an embodiment, the at least one tool is configured to
apply the process on both the rear face and the front face of the
annular flange of the cup.
[0018] That way, a rear sealing profile is created on the rear face
and a front sealing profile is created on the front face.
[0019] In an embodiment, the process on the front face may also be
useful to improve the quality of the lid seal; in effect,
partializing the supporting surface increases the specific pressure
and this has a positive effect on lid crimping. Thus, in an
embodiment, the at least one tool is configured to form on the
front face of the annular flange, a knurled zone suitable for
welding the lid.
[0020] The apparatus preferably comprises an outfeed station
configured to deliver the cups, with the sealing profile formed on
them, to an outlet of the apparatus.
[0021] This disclosure thus provides an apparatus (that is, a
machine) for processing preformed cups to make a sealing profile by
processing the material of the flange of the cup itself. An
apparatus of this kind has several advantages: thanks to the
presence of one or more dedicated tools, it allows the flange to be
processed with a good level of precision, creating a good quality
sealing profile. Moreover, thanks to the apparatus of this
disclosure, it is possible to make high-quality sealing profiles
even with complex geometries; the quality is high even with
different materials and/or colours; the apparatus thus offers great
freedom in the design of the geometries themselves and in the
modifying of the process features.
[0022] Furthermore, the moulding machine may be very simple and
economical to create a cup with simple geometry (which can
subsequently be post-formed by the apparatus of this disclosure to
make a sealing profile with a complex geometry). It should be noted
that this apparatus has a very limited cost compared to the
moulding machine and the cost can be recovered from the saving on
the complexity of the mould and on the flexibility of being able to
change the geometry of the sealing zone without having to change
the mould. In addition, the use of dedicated machinery allows
separating the production of the sealing element spatially and
temporally from the steps of moulding, filling and lid application,
with considerable advantages in terms of process logistics: in
effect, it allows greater flexibility and lowers the rejection rate
(number of defective pieces). Moreover, the apparatus can be
installed in line, after the moulding machine, so as to make the
most of the temperature of the cup, which is still high, when the
flange is still soft and easily deformable (without having to
provide additional heat).
[0023] The apparatus preferably comprises a rotary carousel. The
pockets of the plurality of pockets are preferably angularly spaced
on the carousel (mounted on the carousel).
[0024] For each pocket of the plurality of pockets, the apparatus
preferably comprises a respective tool, which rotates as one with
the carousel and which is configured to apply a process to the rear
face (or the front face) of the annular flange of the cup housed
inside (or received in or supported on) the pocket. Thus, the at
least one tool is mounted on the carousel. Preferably, each pocket
mounted on the carousel is provided with a respective tool,
configured to process the annular flange of the cup located in that
pocket.
[0025] In an embodiment, the at least one tool is configured to
apply a mechanical force on the rear face (or the front face) of
the annular flange of the cup. The at least one tool has an annular
shape so that it can interact with the annular flange of the
capsule along the perimeter of the annular flange. In an
embodiment, the at least one tool is configured to make the sealing
element by moving the material of the annular flange. In an
embodiment, the at least one tool includes a cavity which
corresponds to a protrusion on the abutment element so that
pressing the abutment element against the tool displaces (lowers) a
part of the annular flange.
[0026] In an embodiment, the at least one tool is configured to
make the sealing element by squeezing the material of the annular
flange in such a way as to create a thinned zone and a thickened
zone. In an embodiment, the at least one tool is configured to
produce localized thinning by squeezing the annular flange between
the at least one tool and a respective abutment element.
[0027] In an embodiment, the at least one tool includes a body (or
main body) and one or more protrusions (or protuberances) extending
from the body. In an embodiment, the body has an annular shape. In
an embodiment, the one or more protrusions are annular in shape
(for example, the tool has a plurality of protrusions shaped like
concentric rings. The one or more protrusions define a shaped zone.
The one or more protrusions are configured to thin the flange by
penetrating the rear face thereof. In an embodiment, the at least
one protrusion includes an angled surface.
[0028] In an embodiment, the apparatus comprises a corresponding
abutment element associated with the at least one tool.
[0029] In an embodiment that comprises a plurality of tools
(located in the plurality of pockets), the apparatus comprises a
corresponding plurality of abutment elements.
[0030] In an embodiment, the at least one tool and the
corresponding abutment element are movable between an open
configuration, in which they are spaced apart, and a closed
configuration, in which they are close together and the abutment
element is in contact with the front face of the annular flange and
the one or more protrusions of the at least one tool penetrate the
annular flange, impressing the sealing profile therein. In an
embodiment, the at least one tool comprises a respective actuator
(for example, mechanical, hydraulic or pneumatic) to move it
towards (and away from) the abutment element between the open
configuration and the closed configuration. In an embodiment, the
abutment element corresponding to the at least one tool comprises a
respective actuator (for example, mechanical, hydraulic or
pneumatic) to move it towards (and away from) the tool between the
open configuration and the closed configuration. Thus, in an
embodiment, the sealing profile is obtained by squeezing the flange
between the tool and the abutment element so as to displace the
material of the flange; more specifically, the protrusion (or the
protrusions) of the tool cause localized thinning of the
flange.
[0031] In an embodiment, the abutment element is radially symmetric
about its axis of symmetry.
[0032] In an embodiment, the abutment element includes a contact
surface configured to come into abutment against the front face of
the flange. The contact surface is preferably planar (that is,
flat). The abutment element has an annular shape so that it can
interact with the annular flange of the capsule along the perimeter
of the annular flange. In an embodiment, the abutment element
includes a centring body projecting from the contact surface. In
the closed configuration, the centring body at least partly enters
the containment body of the cup, thus providing a centring effect
on the cup. Preferably, the at least one tool includes a respective
heating element configured to heat the at least one tool. The
heating element may comprise electrical resistors located inside
the tool. The heating element may comprise one or more ultrasonic
emitters configured to cause the at least one tool (in contact with
the annular flange) to vibrate. That way, the tool transmits heat
to the annular flange (thus softening it and making it easier to
process). In this embodiment, processing the flange to make the
sealing element may include thermoforming.
[0033] In an embodiment, the abutment element comprises a
respective heating element configured to heat the abutment element.
The heating element may comprise electrical resistors located
inside the abutment element. The heating element may comprise one
or more ultrasonic emitters configured to cause the abutment
element (in contact with the annular flange) to vibrate.
[0034] In an embodiment, for each pocket of the plurality of
pockets, the apparatus comprises a heater configured to heat the
annular flange of the cup located in the pocket. The heater may
comprise a fan and one or more electrical resistors configured to
heat the air and direct it towards the cup located in the pocket.
The heater may comprise ultrasonic emitters configured to cause the
pocket (hence the cup located in the pocket) to vibrate, thereby
producing heat by friction. In this embodiment, processing the
flange to make the sealing element may include thermoforming.
[0035] In other embodiments, the process used to obtain the sealing
element from the flange is a cold process (performed without
heating the flange, the tool or the abutment element).
[0036] In one embodiment, the apparatus comprises a control unit.
The control unit is configured to control the at least one
tool.
[0037] The control unit is preferably specific to the apparatus.
Thus, the process performed on the flange by the apparatus can be
controlled independently of the cup forming, filling and lid
welding processes.
[0038] In an embodiment, the at least one tool includes a milling
cutter configured to remove material from the rear face (or the
front face) of the annular flange to form the sealing profile. In
an embodiment, the milling cutter has an annular profile. In an
embodiment, the milling cutter is movable along an annular
path.
[0039] In an embodiment, the apparatus comprises ultrasonic
emitting devices associated with the at least one tool. In an
embodiment, the ultrasonic emitting devices are included in the
tool (for example, in the body of the tool). The ultrasonic
emitting devices are configured to heat the annular flange by
causing the at least one tool, which is in contact with the annular
flange, to vibrate.
[0040] In an embodiment, the apparatus comprises ultrasonic
emitting devices associated with the at least one abutment
element.
[0041] In an embodiment, the tool (or rather, each tool) includes a
plurality of processing elements which can be activated selectively
as a function of the type (shape) of sealing profile to be
made.
[0042] In an embodiment, the processing elements may include laser
emitters; in other embodiments, the processing elements may include
jets of hot air or micro cutters, to give but some examples.
Hereinafter, for simplicity of description, we refer to the example
in which laser emitters are used without thereby intending to limit
the scope of the disclosure.
[0043] In an embodiment, the laser emitters are associated with the
at least one tool. In an embodiment, the laser emitters are
disposed on a surface of the tool. The laser emitters are
configured to emit laser rays on (directed at) the rear face of the
annular flange. In an embodiment, the laser rays may be used to
heat the flange prior to mechanical processing. The sealing profile
might also be formed by a laser machining process.
[0044] In one embodiment, the apparatus comprises a control unit.
The control unit is programmed to (selectively) switch on the laser
emitters of the plurality of laser emitters. More specifically, the
control unit is programmed to switch on a part of the plurality of
emitters as a function of a user-set type of sealing profile. In an
embodiment, the memory of the control unit contains a plurality of
patterns corresponding to different types (shapes, forms) of the
sealing profile and the control unit is configured to switch on the
laser emitters along the pattern corresponding to the type of
sealing profile selected by the user. In an embodiment, the
apparatus comprises a die block (preferably fixed, i.e. not rotary)
in which the pockets of the plurality of pockets are disposed. is
In an embodiment, the infeed station is configured to place the
cups in the pockets on the die block. In an embodiment, the infeed
station consists of an arm (or a plurality of arms) configured to
place the cups in the pockets on the die block.
[0045] In an embodiment, the cups placed in the pockets are
processed simultaneously. In effect, the apparatus comprises a tool
(and preferably a respective abutment element) for each pocket. The
tool may be defined by a single-impression moulding machine having
a plurality of annular mouldings surrounding the pockets which
accommodate the cups. The die block itself may define the tool. In
an embodiment, the abutment elements are integrated in a
counter-die block. In an embodiment, the control unit is programmed
to move the counter-die block close to the die block so as to press
the flanges against the tools (that is, the mouldings) of the die
block. In an embodiment, the control unit is programmed to move the
die block close to the counter-die block so as to press the flanges
against the tools (that is, the mouldings) of the die block. That
way, the sealing profile is made by creating an impression between
the die block and the counter-die block.
[0046] In an embodiment, the outfeed station is configured to
remove the cups from the pockets after the sealing profile has been
formed. In an embodiment, the outfeed station consists of an arm
(or a plurality of arms) configured to remove the cups from the
pockets on the die block. In an embodiment, an arm (or a plurality
of arms) has the function both of placing the cups in the die block
and of removing them (hence, the infeed station and the outfeed
station are integrated in a single arm/plurality of arms).
[0047] In an embodiment, the apparatus comprises a processing unit
comprising the at least one tool. In an embodiment, the pockets of
the plurality of pockets are movable relative to the processing
unit (preferably on a conveyor belt). In an embodiment, the
processing unit is configured to process the flange of one cup at a
time, when the pocket containing the cup is located at (that is,
passes by) a processing zone of the conveyor belt. For example, the
at least one tool might comprise a first and a second tool, each
configured to process one half (that is, a semicircle) of the rear
face of the annular flange; the first and second tools are movable
between an open position (spaced apart, where one is positioned on
one side of the conveyor belt and the other on the opposite side)
and a closed position (close together). The control unit is
configured to keep the first and second tools at the open position
while the conveyor belt moves and to bring them to the closed
position when the conveyor belt stops, to allow the tools to come
into contact with the cup to make the sealing profile. When the
first and second tools are at the closed position, the control unit
might also move an abutment element closer to bring it into contact
with the front face of the annular flange; the abutment element may
be configured to press the annular flange against the first and the
second tool.
[0048] This disclosure also relates to a line for making coffee
capsules.
[0049] In an embodiment, the line comprises a forming machine
configured to form the cups. In an embodiment, the forming machine
comprises a plurality of moulds defining forming cavities in which
the cups are formed.
[0050] Preferably, the forming machine is configured to form the
cups by compression moulding.
[0051] In an embodiment, the forming machine is configured to form
the cups by injection moulding. In an embodiment, the forming
machine is configured to form the cups by thermoforming. In an
embodiment, the forming machine is configured to form the cups by
injection compression moulding.
[0052] In an embodiment, the line comprises an apparatus for
processing the cups (of the type described above).
[0053] In an embodiment, the line comprises a filling machine
configured to fill the cups with coffee (and/or other ingredients
for infusion beverages). In an embodiment, the line is configured
to transfer the cups from the forming machine to the apparatus for
processing the cups.
[0054] In an embodiment, the line is configured to transfer the
cups, with the sealing profile formed (released by an outfeed
station of the apparatus for processing the cups) to an infeed
station of the filling machine.
[0055] In an embodiment, the line comprises an applicator machine,
configured to apply a lid to the front face of each cup to form a
respective capsule. In an embodiment, the applicator machine
comprises a welding device configured to weld the lid to the cup.
In an embodiment, the welder also acts as an abutment for the at
least one tool.
[0056] This disclosure also provides a method for processing
plastic cups adapted to be filled with coffee and to be closed with
respective lids to form coffee capsules.
[0057] In an embodiment, the method comprises a step of receiving
the cups at an infeed station of an apparatus for processing the
cups.
[0058] In an embodiment, the method comprises a step of placing the
cups in respective pockets of the apparatus.
[0059] In an embodiment, the method comprises a step of applying a
process to the rear face (or the front face) of the annular flange
of a cup which is housed inside (or received in or supported on) a
respective pocket of the plurality of pockets, so as to form a
sealing profile. In an embodiment, the process is carried out by at
least one tool of the apparatus.
[0060] In an embodiment, the method comprises a step of releasing
the cups, with the sealing profile formed on them, to an outfeed
station of an apparatus.
[0061] In an embodiment, during the step of applying the process,
the at least one tool applies a mechanical force on the rear face
(or the front face) of the annular flange of the cup. In an
embodiment, the tool includes a main body and one or more
protrusions which extend from the main body and which, during the
step of applying the process, penetrate the annular flange,
impressing the sealing profile therein.
[0062] In an embodiment, the tool includes a main body and one or
more protrusions extending from the main body, and during the step
of applying the process, the one or more protrusions move along an
annular profile (by means of a specific actuator).
[0063] In an embodiment, during the step of applying the process,
the tool comes into abutment against a respective abutment
element.
[0064] In an embodiment, the abutment element and the tool
associated therewith are movable between an open configuration, in
which they are not in contact with the annular flange, and a closed
configuration, in which the abutment element (with a contact
surface of it) is in contact with the front face of the annular
flange and the one or more protrusions of the tool penetrate the
annular flange, impressing the sealing profile therein. In an
embodiment, during the step of applying the process, the abutment
element and the tool are in the closed configuration.
[0065] In an embodiment, the abutment element includes a contact
surface, which, during the step of applying the process, comes into
abutment against the front face of the flange, and a centring body
which projects from the contact surface. In an embodiment, during
the step of applying the process, the centring body at least partly
enters the containment body of the cup, thus providing a centring
effect on the cup.
[0066] In an embodiment, the sealing profile is formed by
displacing the material of the flange. Displacement may be obtained
by squeezing or by removal.
[0067] In an embodiment, the step of applying the process includes
a step of removing material from the rear face (or the front face)
of the annular flange to form the sealing profile (by means of a
milling cutter).
[0068] In an embodiment, the method comprises a step of heating the
at least one tool. In an embodiment, the step of heating the at
least one tool precedes the step of applying the process. In an
embodiment, the step of heating the at least one tool is
simultaneous with the step of applying the process. In an
embodiment, the step of heating the at least one tool comprises
ultrasonic vibration of the at least one tool. In an embodiment,
the step of heating the at least one tool comprises heating the at
least one tool by means of electrical resistors.
[0069] In an embodiment, the method comprises a step of heating the
annular flange of the cup located in the pocket. In an embodiment,
the step of heating the annular flange precedes the step of
applying the process. In an embodiment, the step of heating the
annular flange is simultaneous with the step of applying the
process. In an embodiment, the step of heating the annular flange
of the cup comprises ultrasonic vibration of the cup.
[0070] In an embodiment, the method comprises a step of emitting
ultrasounds which cause the at least one tool to vibrate. In an
embodiment, the step of emitting ultrasounds follows the step of
applying the process (so as to facilitate removing the tool). In an
embodiment, the step of emitting ultrasounds precedes the step of
applying the process (so as to heat the flange).
[0071] In an embodiment, the method comprises a step of emitting
laser rays by means of a plurality of laser emitters associated
with the at least one tool. In an embodiment, the step of emitting
laser rays precedes the step of applying the process (so as to heat
the flange). In an embodiment, the step of emitting laser rays is
included in the step of applying the process.
[0072] In an embodiment, the method comprises a step of setting a
sealing profile selected by the user. In an embodiment, the step of
emitting laser rays comprises switching on a part of the plurality
of emitters as a function of a user-set sealing profile.
[0073] In an embodiment, the method (that is, the step of applying
the process) comprises a step of directing pressurized liquid at
the annular flange in order to create the sealing profile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] These and other features will become more apparent from the
following detailed description of a preferred embodiment,
illustrated by way of non-limiting example in the accompanying
drawings, in which:
[0075] FIG. 1 shows an apparatus for processing cups according to
this disclosure;
[0076] FIGS. 2A and 2B show a tool and a corresponding abutment
element of a possible embodiment of the apparatus of FIG. 1
respectively in a closed configuration to impress a sealing profile
on a cup and in an open configuration after the sealing profile has
been formed;
[0077] FIGS. 3A and 3B, 4A and 4B, 5A and 5B, 6A and 6B show
possible variant embodiments of the tool and of the corresponding
abutment element of FIGS. 2A and 2B in the closed configuration and
in the open configuration, respectively;
[0078] FIGS. 7, 8 and 9 show possible variant embodiments of the
tool of the apparatus of FIG. 1;
[0079] FIGS. 9A. 9B and 9C show the tool of FIG. 9 in respective
processing positions;
[0080] FIG. 10A shows a possible variant embodiment of the
tool;
[0081] FIG. 10B shows the cup formed by the variant embodiment of
FIG. 10A, with a lid applied thereon.
[0082] FIG. 11 shows a perspective view of a carousel of the
apparatus of FIG. 1;
[0083] FIG. 12 shows an axial cross section of a pocket of the
carousel of FIG. 11 with a cup housed therein;
[0084] FIG. 13 shows a top view of a pocket of the carousel of FIG.
11;
[0085] FIG. 14 shows a variant embodiment of the carousel of FIG.
11;
[0086] FIG. 15 shows a carousel pocket, with a cup housed inside
it, in a possible variant embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0087] With reference to the accompanying drawings, the numeral 1
denotes an apparatus for processing cups 2.
[0088] Each cup includes a containment body 21. Each cup includes a
bottom wall 22. Each cup includes an annular flange or flange-like
rim 23. The annular flange 23 extends around an axis A of the cup.
The annular flange 23 has a rear face 23B facing towards the
containment body 21. The annular flange 23 has a front face 23A
opposite to the rear face 23B. The top face 23A is adapted to
receive a lid 7 (after the cup has been filled) to form a capsule.
In an embodiment, the apparatus 1 comprises a processing carousel
5. The apparatus 1 comprises a plurality of processing pockets 50,
disposed on the processing carousel 5. Preferably, the pockets 50
are angularly equispaced on the processing carousel 5. The pockets
50 are configured to house the cups 2 during processing. The
processing carousel 5 rotates about its axis of rotation C. For
each processing pocket 50, the apparatus 1 comprises a respective
processing station 10. The processing station 10 is configured to
process a cup 2 housed in the corresponding pocket 50.
[0089] The apparatus 1 comprises an infeed station 4. In an
embodiment, the infeed station 4 is structured like an infeed
carousel. The infeed carousel rotates about its axis of rotation B.
The infeed carousel comprises a plurality of insertion pockets 40.
The infeed carousel is configured to feed the cups 2 to the
processing carousel 5. Thus, the preformed cups 2 are fed to the
insertion pockets 40 and from there to the pockets 50 of the
processing carousel 5.
[0090] The apparatus 1 comprises an outfeed station 6. In an
embodiment, the outfeed station 6 is structured like an outfeed
carousel. The outfeed carousel rotates about its axis of rotation
D. The outfeed carousel comprises a plurality of outfeed pockets
60. The outfeed carousel is configured to receive the cups 2, with
the sealing profile formed on them, from the carousel 5. Thus, the
cups 2 with the sealing profile formed on them are released from
the pockets 50 of the processing carousel 5 and placed in the
outfeed pockets 60.
[0091] For each pocket 50 of the processing carousel 5, the
apparatus 1 comprises a respective tool 31 (the tool is preferably
included in the processing station 10 corresponding to the pocket
50). The tool 31 is disposed in the respective pocket 50. The tool
31 rotates as one with the processing carousel 5 about its axis of
rotation C.
[0092] In an embodiment, the tool 31 is configured to form a
sealing profile 230 on the rear face 23B of the flange 23 of the
cup 2 inside the respective pocket 50.
[0093] In an embodiment, the tool 31 is configured to form a
sealing profile 230 on the front face 23A of the flange 23 of the
cup 2 inside the respective pocket 50.
[0094] For each pocket 50 of the processing carousel 5, the
apparatus 1 comprises a respective abutment element 32 (the
abutment element 32 is preferably included in the processing
station 10 corresponding to the pocket 50). The abutment element 32
is associated with the tool 31 of the respective pocket 50.
[0095] For each pocket 50 of the processing carousel 5, the
apparatus 1 may also comprise a respective centring device 8,
configured to facilitate centring the cup 2 in the pocket 50. The
centring device 8 is connected to the carousel 5. In the embodiment
illustrated, the centring device 8 defines a central cavity in
which the cup 2 is housed. More specifically, the centring device 8
includes a first part and a second part, each of which delimits a
half of the cavity the cup is housed in; the first part and the
second part may be movable towards and away from each other.
[0096] In an embodiment, the tool 31 extends symmetrically about
its axis of symmetry. In an embodiment, the tool 31 includes a body
310 (or main body).
[0097] In an embodiment, the tool 31 includes at least one
protrusion (or protuberance) 311 projecting from the body 310. In
an embodiment, the at least one protrusion 311, has an annular
shape. In an embodiment, the at least one protrusion 311, has a
broken annular profile. In an embodiment, the tool 31 includes a
protrusion 311. In an embodiment, the tool 31 includes two
protrusions 311 (spaced from each other). In an embodiment, the
tool 31 includes three protrusions 311 (spaced from each other). In
an embodiment, the tool 31 includes four protrusions 311 (spaced
from each other). In an embodiment, the one or more protrusions 311
are triangular in shape. In an embodiment, the one or more
protrusions 311 are trapezoidal in shape.
[0098] In an embodiment, the abutment element 32 comprises a body
320. In an embodiment, the abutment element 32 comprises a flat
contact surface 322. The contact surface 322 is configured to come
into contact with the top face is 23A of the annular flange 23
(acting as an abutment for the tool 31).
[0099] In an embodiment, the tool 31 and the respective abutment
element 32 are movable between an open configuration and a closed
configuration. In the open configuration, the tool 31 and the
respective abutment element 32 are spaced from each other. The open
configuration is suitable for inserting the cup 2 into the pocket
50 and for removing the cup 2 from the pocket 50. In the closed
configuration, the tool 31 and the respective abutment element 32
are close together: the abutment element 32 is in contact with the
top surface 23A of the flange 23, while the at least one protrusion
311 of the tool 31 penetrates the rear face 23B of the flange 23,
deforming it and impressing a sealing profile 230 in it. In an
embodiment, the annular flange 23 has a thickened zone which the at
least one protrusion 311 penetrates. In an embodiment, in the
closed configuration, the flat contact surface 322 comes into
contact with the front surface 23A without deforming it.
[0100] At least one between the tool 31 and the abutment element 32
is movable relative to the carousel 5 to be positioned between the
open configuration and the closed configuration. More specifically,
for each tool 31, the apparatus 1 comprises a respective actuator
314 (for example, a reduction gear motor) configured to move the
tool 31 in parallel with the axis C of the carousel 5.
Alternatively, or in addition, for each abutment element 32, the
apparatus 1 may comprise a respective actuator 324 (for example, a
reduction gear motor) configured to move the abutment element 32 in
parallel with the axis C of the carousel 5.
[0101] In an embodiment, the tool 31 and the abutment element 32
are connected to the carousel 5 (that is, are mounted on the
carousel); in this embodiment, the actuator 314 of the tool 31
and/or the actuator 324 of the abutment element are also mounted on
the carousel 5.
[0102] In an embodiment, the carousel 5 comprises a top plate 5A,
on which the abutment elements 32 are mounted, and a bottom plate
5B, on which the tools 31 are mounted; the top plate 5A is parallel
to the bottom plate 5B and rotates about the same axis of rotation
C. The tools 31 are movable relative to the bottom plate 5B,
towards and away from the bottom plate 5B (by means of the actuator
314), and/or the abutment elements 32 are movable relative to the
top plate 5A, towards and away from the top plate 5A (by means of
the actuator 324), in addition or in alternative, the top plate 5A
and the bottom plate 5B are movable relative to each other, towards
and away from each other.
[0103] In an embodiment, each pocket 50 of the carousel 5 comprises
a supporting element 35 to supportably receive the bottom wall 22
of the cup 2. In an embodiment, the supporting element 35 is
connected by a spring 34 (also included in the pocket 50) to a
supporting surface 340; the supporting element 35 is movable
relative to the supporting surface 340 by means of the spring 34.
That way, when the tool 31 moves away from the abutment element 32,
the spring 34 pushes the cup out of the pocket 50. In the case
where the carousel 5 includes a top plate 5A and a bottom plate 5B,
the supporting element 35, the spring 34 and the supporting surface
340 are preferably connected to the bottom plate 5B. The tool 31
may be mounted on the supporting surface 340 fixedly or
movably.
[0104] In an embodiment, the tool 31 includes a cavity 312 hollowed
out in the main body 310.
[0105] In an embodiment, the abutment element 32 comprises at least
one protrusion (or protuberance) 321 projecting from the body 320
of the abutment element 32 (that is, from the contact surface 322).
In an embodiment, the abutment element 32 comprises a protuberance
321. In an embodiment, the at least one protrusion 321, has an
annular shape. In an embodiment, the at least one protrusion 321,
has a broken annular profile. In an embodiment, the abutment
element 32 comprises two protuberances 321 (spaced from each
other). In an embodiment, the abutment element 32 comprises three
protuberances 321 (spaced from each other). In an embodiment, the
abutment element 32 comprises four protuberances 321 (spaced from
each other). In an embodiment, in the closed configuration, the one
or more protrusions 321 of the abutment element 32 penetrate the
front face 23A of the annular flange 23, impressing a shape
therein.
[0106] In an embodiment, in the closed configuration, the one or
more protrusions 321 of the abutment element push the material of
the annular flange 323 into the cavity 312 of the tool, creating
the sealing profile 320 by displacing the material of the annular
flange.
[0107] In an embodiment, the abutment element 32 is radially
symmetric about its axis of symmetry. In an embodiment, the
abutment element 32 comprises a centring body 323 projecting from
the contact surface 322 (and from the body 320). In an embodiment,
the centring body 323 in the closed configuration (at least partly)
enters the containment body 21 of the cup 2. That way, the centring
body 323 provides a centring effect on the cup 2 in the pocket 50
such that the axis A of the cup 2 is made to correspond to the axis
of symmetry of the abutment element 32 and to the axis of symmetry
of the tool 31.
[0108] In an embodiment, tool 31 comprises a first part 31A and a
second part 31B. In an embodiment, the tool 31 comprises a
plurality of parts. In an embodiment, each part 31A, 31B is movable
independently towards and away from the flange 23. In an
embodiment, the control unit is programmed to activate (that is,
move to the closed configuration) only the first part 31A or only
the second part 31B or both the first and the second part 31A and
31B in succession, depending on the geometry of the sealing profile
230 required. Dividing the tool into two or more parts allows a
high level of flexibility in the production of the sealing
profiles: in particular, it allows easily varying the geometry and
making the complex geometries with a good degree of precision.
[0109] In an embodiment, the apparatus comprises a centring tool 33
for each pocket. The centring tool 33 may be provided alternatively
to, or in combination with, the centring device 8. In an
embodiment, the centring tool 33 has an annular shape. In an
embodiment, the centring tool 33 surrounds the tool 31.
[0110] In an embodiment, the control unit is programmed to activate
the centring tool 33 first (to bring it into contact with the
flange 23) and then the tool 31. In an embodiment, the centring
tool 33 surrounds the first part 31A of the tool 31 and the first
part surrounds the second part 31B. In an embodiment, the control
unit is programmed to activate the centring tool 33 first (to bring
it into contact with the flange 23) and then to activate the first
part 31A (followed, if necessary, by the second part 31B). In an
embodiment, the control unit is programmed to activate the centring
tool 33 first (to bring it into contact with the flange 23) and
then to activate the second part 31B (followed, if necessary, by
the first part 31A). In an embodiment, the control unit is
programmed to activate the centring tool 33 first (to bring it into
contact with the flange 23) and then to activate the first part 31A
and the second part 31B simultaneously.
[0111] In an embodiment, the tool 31 comprises a plurality of laser
emitters 312. In an embodiment, the tool 31 is configured to make
the sealing profile 230 by optical processing of the rear face 23B
of the flange 23. In an embodiment, the tool 31 is configured to
make the sealing profile 230 by optical processing of the front
face 23A of the flange 23.
[0112] In an embodiment, the tool 31 comprises a plurality of
nozzles 313. In an embodiment, the tool 31 is configured to make
the sealing profile 230 by directing pressurized liquid at the rear
face 23B of the flange 23. In an embodiment, the tool 31 is
configured to make the sealing profile 230 by directing pressurized
liquid at the front face 23A of the flange 23. In an embodiment,
the control unit activates a part of the nozzles 313 as a function
of the shape of the sealing profile 230 required.
[0113] The following paragraphs, listed in alphanumeric order for
reference, are non-limiting example modes of describing this
invention.
[0114] A000. An apparatus for processing plastic cups adapted to be
filled with a product and to be closed with respective lids to form
capsules, wherein each cup includes a containment body, which
extends between a bottom wall and an upper edge, and an annular
flange having a rear face, directed towards the containment body,
and a front face, adapted to receive the lid to form the capsule,
the apparatus comprising: [0115] at least one pocket, configured to
receive (or house) the cup; [0116] at least one tool, configured to
apply a process to at least the rear face or the front face of the
annular flange of a cup received (or housed) in the pocket, so as
to form a sealing profile.
[0117] A00. The apparatus of paragraph A000, comprising a plurality
of pockets configured to receive (or house) a corresponding
plurality of cups.
[0118] A0. The apparatus of paragraph A000 or paragraph A00,
comprising an infeed station configured to receive the cups (or the
cup) and to place them in (or support them on) respective pockets
of the plurality of pockets (or in the at least one pocket).
[0119] A. The apparatus of any one of paragraphs from A000 to A0,
comprising an outfeed station configured to deliver the cups (or
the cup), with the sealing profile formed on them, to an outlet of
the apparatus.
[0120] A1. The apparatus of any one of paragraphs from A000 to A,
wherein the at least one tool is configured to apply a mechanical
force on the rear face of the annular flange of the cup.
[0121] A1.1. The apparatus of any one of paragraphs from A000 to
A1, wherein the at least one tool is configured to apply a
mechanical force on the front face of the annular flange of the
cup.
[0122] A2. The apparatus of any one of paragraphs from A000 to
A1.1, comprising, for each tool, a respective abutment element
associated with the tool.
[0123] A2.1. The apparatus of paragraph A2, wherein the abutment
element is radially symmetric about its axis of symmetry.
[0124] A2.2. The apparatus of paragraph A2 or of paragraph A2.1,
wherein the abutment element includes a centring body.
[0125] A2.3. The apparatus of any one of paragraphs from A2 to
A2.2, wherein the tool includes a main body and one or more
protrusions which extend from the main body.
[0126] A2.3.1. The apparatus of paragraph A2.3, wherein the one or
more protrusions are radially symmetrical.
[0127] A2.3.1.1. The apparatus of paragraph A2.3.1, wherein the one
or more protrusions have an annular profile.
[0128] A2.3.2. The apparatus of paragraph A2.3 or of paragraph
A2.3.1.1, wherein the one or more protrusions are movable along an
annular profile (by means of a specific actuator).
[0129] A2.3.3. The apparatus of any one of paragraphs from A2.3 to
A2.3.2, wherein the abutment element and the tool associated
therewith are movable between an open configuration, in which they
are not in contact with the annular flange, and a closed
configuration, in which the abutment element (with a contact
surface of it) is in contact with the front face of the annular
flange and the one or more protrusions of the tool penetrate the
annular flange, impressing the sealing profile therein.
[0130] A2.3.3.1. The apparatus of paragraph A2.3.3, wherein the
abutment element includes a contact surface, configured to come
into abutment against the front face of the flange, and a centring
body which projects from the contact surface and which, in the
closed configuration, at least partly enters the containment body
of the cup, thus providing a centring effect on the cup.
[0131] A2.3.4. The apparatus of any one of paragraphs from A2.3 to
A2.3.3.1, wherein the tool is configured to make the sealing
profile by squeezing the material of the flange.
[0132] A2.4. The apparatus of any one of paragraphs from A2 to
A2.3.4, wherein the tool includes a main body and a cavity made in
the main body, and wherein the abutment element includes at least
one main body and at least one protrusion projecting from the main
body and configured to displace the material of the flange inside
the cavity, thereby impressing the sealing profile.
[0133] A2.4.1 The apparatus of paragraph A2.4, wherein the one or
more protrusions of the abutment element and the cavity of the tool
are radially symmetrical.
[0134] A2.4.1.1. The apparatus of paragraph A2.4.1, wherein the one
or more protrusions of the abutment element and the cavity of the
tool have an annular profile.
[0135] A2.4.2. The apparatus of paragraph A2.4 or of paragraph
A2.4.1.1, wherein the one or more protrusions of the abutment
element are movable along an annular profile (by means of a
specific actuator).
[0136] A2.4.3. The apparatus of any one of paragraphs from A2.4 to
A2.4.2, wherein the abutment element and the tool associated
therewith are movable between an open configuration, in which they
are not in contact with the annular flange, and a closed
configuration, in which the abutment element (with a contact
surface of it) is in contact with the front face of the annular
flange and the one or more protrusions of the tool cause a
displacement of the material of the annular flange, thereby
impressing the sealing profile therein.
[0137] A2.4.3.1. The apparatus of paragraph A2.4.3, wherein the
abutment element includes a contact surface, configured to come
into abutment against the front face of the flange, and a centring
body which projects from the contact surface and which, in the
closed configuration, at least partly enters the containment body
of the cup, thus providing a centring effect on the cup.
[0138] A2.4.4. The apparatus of any one of paragraphs from A2.4 to
A2.4.3.1, wherein the tool is configured to make the sealing
profile by displacing the material of the flange.
[0139] A3. The apparatus of any one paragraphs A2 to A2.4.4,
comprising a circuit (hydraulic or pneumatic) to move the at least
one tool and the respective abutment element between the open
position and the closed position.
[0140] A4. The apparatus of any one of paragraphs from A000 to A3,
wherein the at least one tool is heated.
[0141] A4.1. The apparatus of paragraph A4 wherein the at least one
tool includes a respective heating element.
[0142] A4.1.1. The apparatus of paragraph A4.1, wherein the heating
element includes one or more electrical resistors integrated in a
body of the tool.
[0143] A4.2. The apparatus of paragraph A4 or of paragraph A4.1,
comprising, for each tool, one or more ultrasonic emitters
configured to cause the at least one tool to vibrate (so as to heat
it by ultrasonic vibrations).
[0144] A5. The apparatus of any one of paragraphs from A000 to
A4.2, comprising, for each pocket (or for the at least one pocket),
a heater configured to heat the flange on the cup received (or
housed) in the pocket.
[0145] A5.1. The apparatus of paragraph A5, wherein the heater
comprises a plurality of electrical resistors for heating the air,
and a fan configured to direct the heated air at the flange on the
cup.
[0146] A5.2. The apparatus of paragraph A5 or of paragraph A5.1,
wherein the heater comprises one or more ultrasonic emitters
configured to cause the cup to vibrate (so as to heat it by
ultrasonic vibrations).
[0147] A6. The apparatus of any one of paragraphs from A000 to
A5.2, comprising a control unit configured to control the at least
one tool.
[0148] A6.1. The apparatus of paragraph A6, wherein the control
unit is preferably specific to the apparatus.
[0149] A7. The apparatus of any one of paragraphs from A000 to
A6.1, wherein the at least one tool includes a milling cutter
configured to remove material from the rear face of the annular
flange to form the sealing profile.
[0150] A7.1. The apparatus of paragraph A7, wherein the milling
cutter includes an annular milling cutter profile to make an
annular sealing profile.
[0151] A7.2. The apparatus of paragraph A7 or of paragraph A7.1,
wherein the milling cutter includes a milling cutter bit movable
along an annular path to make an annular sealing profile.
[0152] A7.3. The apparatus of any one of paragraphs from A7 to
A7.2, wherein the milling cutter rotates about its axis of rotation
(by means of a specific actuator).
[0153] A8. The apparatus of any one of paragraphs from A000 to
A7.3, comprising ultrasonic emitters associated with the at least
one tool and configured to cause the at least one tool to
vibrate.
[0154] A9. The apparatus of any one of paragraphs from A to A8,
comprising, in each pocket (or in the at least one pocket) a
plurality of laser emitters associated with the at least one
tool.
[0155] A9.1. The apparatus of paragraph A9, comprising a control
unit programmed to switch on the laser emitters of the plurality of
laser emitters, the control unit being configured to switch on a
part of the plurality of emitters as a function of a user-set type
of sealing profile.
[0156] A9.1.1. The apparatus of paragraph A9, wherein the control
unit contains in its memory one or more patterns corresponding to
shapes for processing the annular flange and is programmed to
receive a signal from a user to select a processing shape and to
drive the laser emitters to emit laser rays according to the
pattern corresponding to the processing shape selected by the
user.
[0157] A10. The apparatus of any one of paragraphs from A000 to
A9.1.1, wherein the tool comprises a plurality of nozzles connected
to a pressurized liquid tank and configured to direct the
pressurized liquid at the annular flange to form the sealing
profile.
[0158] A11. The apparatus of any one of paragraphs from A000 to
A10, wherein the at least one tool comprises a plurality of parts,
wherein each part of the plurality of parts is movable towards and
away from the flange independently of the other parts of the
plurality of parts.
[0159] A11.1. The apparatus of paragraph A11, wherein the plurality
of parts is made up of a first part and a second part.
[0160] A11.2. The apparatus of paragraph A11 or of paragraph A11.1,
wherein the parts are annular in shape and are concentric with each
other.
[0161] A11.3. The apparatus of any one of paragraphs from A11 to
A11.2, comprising a control unit programmed to activate one or more
parts of the plurality of parts in a predetermined sequence as a
function of a required sealing profile shape.
[0162] A12. The apparatus of any one of paragraphs from A000 to
A10, wherein the apparatus is built into a forming machine, wherein
the forming machine is configured to form the cups from respective
quantities of material or preforms.
[0163] A12.1. The apparatus of paragraph A12, wherein the forming
machine includes a plurality of moulds configured to form
respective cups and wherein the at least one tool (and, if present,
the respective abutment element) is built into the mould.
[0164] A12.1.1. The apparatus of paragraph A12.1, wherein the at
least one tool is configured to protrude telescopically from the
walls of the mould to impress the sealing profile.
[0165] A12.1.1.1. The apparatus of paragraph A12.1.1, comprising a
control unit programmed to drive the at least one tool (and, if
present, the respective abutment element) to protrude
telescopically from the walls of the mould once the cup has been
formed.
[0166] A12. The apparatus of any one of paragraphs from A000 to
A12.1.1.1, comprising at least one centring tool having an annular
shape.
[0167] A12.1. The apparatus of paragraph A12, wherein the at least
one centring tool surrounds the at least one tool.
[0168] A12.1. The apparatus of paragraph A12, comprising a control
unit programmed to activate the at least one centring tool
(bringing it into contact with the flange) before activating the at
least one tool.
[0169] A13. The apparatus of any one of paragraphs from A000 to
A12.1.1.1, comprising an outfeed station configured to deliver the
formed capsules to an outlet of the apparatus.
[0170] A13.1. The apparatus of paragraph A13, wherein the apparatus
is built into a lid applicator machine configured to apply a lid to
the cup to form the capsule.
[0171] A13.1.1. The apparatus of paragraph A13.1 wherein the lid
applicator machine comprises a welder configured to weld the lid to
the cup and wherein the welder also acts as an abutment element for
the at least one tool.
[0172] A14. The apparatus of any one of paragraphs from A00 to
A13.1.1, comprising a rotary carousel, wherein the pockets of the
plurality of pockets (or the at least one pocket) are angularly
spaced on the carousel.
[0173] A14.1. The apparatus of paragraph A14, including, for each
pocket of the plurality of pockets, a respective rotary tool which
rotates as one with the carousel and which is configured to apply a
process to the rear face of the annular flange of the cup received
(or housed) in the pocket.
[0174] A15. The apparatus of any one of paragraphs from A000 to
A13.1.1, comprising a die block in which the pockets of the
plurality of pockets are disposed.
[0175] A15.1. The apparatus of paragraph A15, wherein the die block
is fixed.
[0176] A15.2. The apparatus of paragraph A15 or of paragraph A15.1,
including a respective tool for each pocket of the plurality of
pockets, wherein the tools of all the pockets of the plurality of
pockets are configured to apply the processes simultaneously on all
the cups received (or housed) in the respective pockets of the
plurality of pockets.
[0177] A16. The apparatus of any one of paragraphs from A000 to
A13.1.1, comprising a processing unit comprising the at least one
tool, wherein the pockets of the plurality of pockets (or the at
least one pocket) are movable relative to the processing unit.
[0178] A16.1. The apparatus of paragraph A16, including a conveyor
belt, wherein the pockets of the plurality of pockets (or the at
least one pocket) are movable on the conveyor belt.
[0179] A16.1.1. The apparatus of paragraph A16.1, wherein the
processing unit is configured to process one flange at a time when
the respective pocket is in a processing zone of the conveyor
belt.
[0180] B00. A line for making capsules, comprising: [0181] a
forming machine configured to form plastic cups, wherein each cup
includes a containment body, which extends between a bottom wall
and an upper edge, and an annular flange having a rear face,
directed towards the containment body, and a front face, opposite
to the rear face; [0182] an apparatus (1) for processing the
plastic cups (2) according to any one of the preceding
paragraphs.
[0183] B0. The line of paragraph B00, comprising a filling machine,
configured to fill the cups with a product; the product may,
depending on the application, be coffee or other infusion product,
or other solid, liquid or creamy food product, or other type of
product (for example a drug).
[0184] B. The line of paragraph B0 or of paragraph B00, comprising
an applicator machine, configured to apply a lid to the front face
of each cup to form a respective capsule.
[0185] B1. The line of any one of paragraphs from B00 to B, wherein
the forming machine comprises: [0186] a plurality of pockets
configured to receive (or house) the cups; [0187] at least one
tool, configured to apply a process to the rear face of the annular
flange of a cup received (or housed) in a respective pocket of the
plurality of pockets (or in the at least one pocket), so as to form
a sealing profile.
[0188] B1.1. The line of paragraph B1, comprising, in the pockets
(or in the at least one pocket) respective moulds (or one mould)
for forming the capsules and (for each pocket) a tool having a rest
position, where it is retracted within the mould, and a working
position, where it projects telescopically from the mould.
[0189] B1.2. The line of paragraphs B1 and B1.1, wherein the line
is configured to transfer the cups, with the sealing profile formed
on them and released by the outfeed station of the forming machine,
to an infeed station of the filling machine.
[0190] B2. The line of any one of paragraphs from B00 to B1.2,
wherein the line is configured to transfer the cups, with the
sealing profile formed on them and released by the outfeed station
of the apparatus for processing the cups, to an infeed station of
the filling machine.
[0191] B3. The line of any one of paragraphs from B00 to B1.2,
wherein the applicator machine comprises: [0192] a plurality of
pockets configured to receive (or house) the cups; [0193] at least
one tool, configured to apply a process to the rear face of the
annular flange of a cup received (or housed) in a respective pocket
of the plurality of pockets so as to form a sealing profile.
[0194] B3.1. The line of paragraph B3, comprising a welder
configured to weld the lid to the front face of the cup and wherein
the welder also acts as an abutment element for the at least one
tool.
[0195] B3.1.1. The line of paragraph B3.1, comprising a control
unit programmed to move the welder and the at least one tool
(preferably simultaneously) from a rest position, in which they are
spaced from the cup, to a working position, in which the welder is
in contact with the front face of the cup and the at least one tool
is in contact with the rear face of the cup in order to make a
sealing profile on the rear face of the cup.
[0196] B4. The line of any one of paragraphs from B00 to B3.1.1,
wherein the forming machine is configured to form the cups by
compression moulding.
[0197] B5. The line of any one of paragraphs from B00 to B3.1.1,
wherein the forming machine is configured to form the cups by
injection moulding.
[0198] B6. The line of any one of paragraphs from B00 to B3.1.1,
wherein the forming machine is configured to form the cups by
thermoforming.
[0199] B7. The line of any one of paragraphs from B00 to B3.1.1,
wherein the forming machine is configured to form the cups by
injection compression moulding.
[0200] C000. A method for processing plastic cups adapted to be
filled with a product and to be closed with respective lids to form
capsules, wherein each cup includes a containment body, which
extends between a bottom wall and an upper edge, and an annular
flange having a rear face, directed towards the containment body,
and a front face, adapted to receive the lid to form the capsule,
the method comprising the following steps: [0201] placing the cup
in at least one pocket of the apparatus; [0202] applying a process
to at least the rear face or the front face of the annular flange
of a cup received (or housed) in the at least one pocket, so as to
form a sealing profile by means of at least one tool.
[0203] C00. The method of paragraph C000, wherein during the step
of placing, a plurality of cups are placed in a respective
plurality of pockets of the apparatus, in which the process is
applied.
[0204] C0. The method of paragraph C000 or of paragraph C00,
comprising a step of receiving the cups and placing them in
respective pockets of the plurality of pockets (or in the at least
one pocket) by means of an infeed station of the apparatus.
[0205] C. The method of any one of paragraphs from C000 to C0,
comprising a step of extracting the cups from the pockets of the
plurality of pockets (or the cup from the at least one pocket) by
means of an outfeed station of the apparatus.
[0206] C1. The method of paragraph C000 or of paragraph C, wherein,
during the step of applying the process, the at least one tool
applies a mechanical force on the rear face of the annular flange
of the cup.
[0207] C1.1. The method of paragraph C000 or of paragraph C1,
wherein, during the step of applying the process, the at least one
tool applies a mechanical force on the front face of the annular
flange of the cup.
[0208] C2. The method of any one of paragraphs from C000 to C1,
wherein, during the step of applying the process, the tool comes
into abutment against a respective abutment element.
[0209] C2.1. The method of paragraph C2, wherein the tool includes
a main body and one or more protrusions extending from the main
body, and during the step of applying the process, the one or more
protrusions are movable along an annular profile (by means of a
specific actuator).
[0210] C2.2. The method of paragraph C2 or of paragraph C2.1,
wherein the abutment element and the tool associated therewith are
movable between an open configuration, in which they are not in
contact with the annular flange, and a closed configuration, in
which the abutment element (with a contact surface of it) is in
contact with the front face of the annular flange and the at least
one tool is in contact with the rear face of the annular flange,
impressing the sealing profile, wherein during the step of applying
the process, the abutment element and the tool are in the closed
configuration.
[0211] C2.2.2. The method of paragraph C2.2 wherein the abutment
element includes a contact surface, which, during the step of
applying the process, comes into abutment against the front face of
the flange, and a centring body which projects from the contact
surface and which, during the step of applying the process, at
least partly enters the containment body of the cup to provide a
centring effect on the cup.
[0212] C3. The method of any one of paragraphs from C000 to C2.2.2,
wherein the tool forms the sealing profile (during the step of
applying the process) by squeezing the material of the flange.
[0213] C3.1. The method of paragraph C3, wherein the tool includes
a main body and one or more protrusions which extend from the main
body and which, during the step of applying the process, penetrate
the annular flange, impressing the sealing profile therein.
[0214] C30. The method of any one of paragraphs from C000 to
C2.2.2, wherein the tool forms the sealing profile (during the step
of applying the process) by displacing the material of the
flange.
[0215] C30.1. The method of paragraph C30, wherein the tool
includes a cavity formed in the main body and wherein the abutment
element includes at least one protrusion which, during the step of
applying the process (with the tool and the abutment element in the
closed configuration), causes the material of the annular flange to
be displaced in the hollow, thereby impressing the sealing profile
therein.
[0216] C4. The method of any one of paragraphs from C000 to C3.1,
comprising a step of heating the at least one tool.
[0217] C4.1. The method of paragraph C4, wherein the step of
heating the at least one tool precedes (or is simultaneous with)
the step of applying the process.
[0218] C4.2. The method of paragraph C4 or of paragraph C4.1,
wherein the step of heating the at least one tool comprises
ultrasonic vibration of the at least one tool.
[0219] C5. The method of any one of paragraphs from C000 to C4.1,
comprising a step of heating the annular flange of the cup received
(or housed) in the pocket.
[0220] C5.1. The method of paragraph C5, wherein the step of
heating the annular flange of the cup precedes (or is simultaneous
with) the step of applying the process.
[0221] C5.2. The method of paragraph C5 or of paragraph C5.1,
wherein the step of heating the annular flange of the cup comprises
ultrasonic vibration of the cup.
[0222] C7. The method of any one of paragraphs from C000 to C5.2,
wherein the step of applying the process includes a step of
removing material from the rear face of the annular flange to form
the sealing profile.
[0223] C7.1. The method of paragraph C7, wherein the step of
removing material includes a step of moving a milling cutter bit
along an annular path.
[0224] C7.2. The method of paragraph C7 or of paragraph C7.1,
wherein the step of removing material includes a step of rotating a
milling cutter about its axis of rotation.
[0225] C8. The method of any one of paragraphs from C000 to C7.2,
comprising a step of emitting ultrasounds which cause the at least
one tool to vibrate.
[0226] C8.1. The method of paragraph C8, wherein the step of
emitting ultrasounds follows the step of applying the process.
[0227] C8.2. The method of paragraph C8, wherein the step of
emitting ultrasounds precedes, or is simultaneous with, the step of
applying the process.
[0228] C9. The method of any one of paragraphs from C000 to C8.2,
comprising a step of emitting laser rays by means of a plurality of
laser emitters associated with the at least one tool.
[0229] C9.1. The method of paragraph C9, wherein the step of
emitting laser rays precedes the step of applying the process.
[0230] C9.2. The method of paragraph C9, wherein the step of
emitting laser rays is included in the step of applying the
process.
[0231] C9.3. The method of any one of paragraphs from C9 to C9.2,
comprising a step of setting a sealing profile selected by the
user, wherein the step of emitting laser rays comprises switching
on a part of the plurality of emitters as a function of the
user-set sealing profile.
[0232] C10. The method of any one of paragraphs from C000 to C9.3,
comprising a step of directing pressurized liquid at the annular
flange in order to create the sealing profile.
[0233] C11. The method of any one of paragraphs from C000 to C10,
wherein the step of applying the process comprises activating one
or more parts of a plurality of parts making up the at least one
tool (that is, moving them towards and into abutment with the
flange).
[0234] C11.1. The method of paragraph C11, wherein the step of
applying the process comprises activating a first part of the at
least one tool and then activating a second part of the at least
one tool.
[0235] C12. The method of any one of paragraphs from C to C10,
wherein the step of applying the process is carried out after a
step of forming the cup, inside a mould of a forming machine,
configured to form the cups from respective measured quantities of
material or preforms.
[0236] C12.1. The method of paragraph C12, comprising a step of
telescopically extracting the at least one tool from the mould.
[0237] C13. The method of any one of paragraphs from C000 to C12.1,
comprising a step of centring the cup inside the pocket, including
a step of activating a centring tool.
[0238] C13.1. The method of paragraph C13, wherein the step of
centring precedes the step of applying the process.
[0239] C13.2. The method of any one of paragraphs from C000 to
C13.1, comprising a step of welding a lid to the front face of the
cup by means of a welder, wherein the step of applying the process
is simultaneous with the step of welding.
[0240] C13.2.1. The method of paragraph C13.2, wherein the welder
also acts as an abutment for the at least one tool.
[0241] C14. The method of any one of paragraphs from C000 to
C13.1.1, comprising a step of rotating the pockets of the plurality
of pockets (or the at least one pocket) on a rotary carousel.
[0242] C14.1. The method of paragraph C14, wherein the step of
applying the process is carried out in each pocket (or in the at
least one pocket) by means of a respective tool which rotates as
one with the carousel.
[0243] C15. The method of any one of paragraphs from C000 to
C13.1.1, wherein the step of applying the process comprises a step
of simultaneously processing a plurality of cups received (or
housed) in respective pockets of a plurality of pockets.
[0244] C15.1. The method of paragraph C15, comprising a step of
placing the cups in the pockets of the plurality of pockets before
the step of applying the process and a step of extracting the cups
from the pockets of the plurality of pockets after the step of
applying the process.
[0245] C16. The method of any one of paragraphs from C000 to
C13.1.1, comprising a step of moving the pockets of the plurality
of pockets (or the at least one pocket) on a conveyor belt.
[0246] C16.1. The method of paragraph C16, wherein the step of
applying the process comprises a step of processing one flange (of
one cup) at a time when the respective pocket is in a processing
zone of the conveyor belt.
[0247] C17. The method of any one of paragraphs from C000 to C16.1,
wherein the step of applying the process comprises a step of
processing the front face of the annular flange of the cup to form
a knurled zone suitable for welding the lid.
[0248] C18. The method of any one of paragraphs from C000 to C17,
wherein the product may, depending on the application, be coffee or
other infusion product, or other solid, liquid or creamy food
product, or other type of product (for example a drug).
* * * * *